Assembling Second-Generation Hybrid Cable

S200, S300, S500, S1700, S2700, S3700, S5700, and S6700 Series Switches Hardware Installation and Component Replacement

This document describes installation procedures of the S200, S300, S500, S1700, S2700, S3700, S5700, and S6700 series switches, troubleshooting methods for common faults, and switch maintenance instructions. From this document, you can obtain information required for installation and maintenance of the S200, S300, S500, S1700, S2700, S3700, S5700, and S6700 series switches.

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Assembling Second-Generation Hybrid Cable

Context

The second-generation hybrid cable (hybrid cable 2.0) is composed of optical fibers and copper cores. It is mainly used to connect a hybrid optical-electrical switch to an AP or remote unit so that the switch can provide power and transmit data for the AP or remote unit. During construction, onsite cable connection is required.

Do not stretch, step on, or place heavy objects on hybrid cables 2.0. Keep the cables away from sharp objects. A maximum of 100 hybrid cables 2.0 can be bundled when no pipe is used. When a pipe is used, ensure that one-third space inside the pipe is vacant.
Cabling is allowed only when communication facilities are available. Preparing cables onsite must be performed with no power supply connected. After hybrid cables 2.0 are made onside, you are advised to use a red pointer and an optical fiber adapter to check whether optical fibers are broken or not.
Route cables according to the planned positions and mark the cables in advance to eliminate the need to differentiate cables on the switch side after the cables are routed. Reserve a sufficient length of cable at the end where the cable label is attached, avoiding cutting off the cable label during cable assembling.
When routing hybrid cables 2.0, coil the excess optical fibers around dedicated devices, such as a fiber management tray. Even force needs to be applied when cables are coiled to ensure the cables are not overly bent. The bending radius of a hybrid cable 2.0 is at least five times its diameter. The minimum bending radius of a branch optical fiber inside a hybrid cable 2.0 is 15 mm.
Vacant hybrid connectors must be covered with dustproof caps. Ensure that the end faces of hybrid connectors are clean. When a hybrid connector is installed or removed, protect its end face from touching other objects, preventing contamination or damage. If any dirt is found, use alcohol or dust-free paper to clean it. If the end face is damaged, start from the very beginning to assemble the pigtail.
After connecting the pigtails on both sides of a hybrid cable, you need to test the link loss. If the fiber splicing or cable crimping does not meet the requirements, you are advised to cut off the connection point between the main cable and the pigtail and then reconnect them.
The connector of a hybrid cable 2.0 cannot be inserted into a common optical module and must be used with a hybrid module (SFP-GE-Hybrid or SFP-10G-Hybrid).
After splicing optical fibers and crimping power cables in one hybrid cable are complete, make another hybrid cable.

Tools and Accessories

Table 3-22 Fusion splicing tools (prepared by the customer)

Tool	Appearance	Description
Cable stripper		Used to peel off the outer sheath of hybrid cables.
Wire stripper		Used to peel off the rubber layer and coating layer of hybrid cables, and only involved in fusion splicing scenarios.
Fiber cleaver		Used to cut optical fibers.
Duckbilled wire stripper		Used to remove the rubber layer of copper cores in hybrid cables.
Fiber cleaning paper and alcohol (concentration: 99.5%)	-	Used to clean optical fibers.
Optical fiber splicer		Used to fusion splice the optical fiber and pigtail, and only involved in fusion splicing scenarios.
Crimping tool		Used to connect power cables.
Long measuring tape		Used to measure dimensions.
Insulation tape		Used to fix cables or wrap the damaged part for protection.
Red pointer		Used to test the connectivity of optical fibers.

Table 3-23 Accessories

Tool	Part Number	Description
Heat shrink tubing	02233PJA	Used only in fusion splicing scenarios.
Fiber splice protector		Used only in fusion splicing scenarios.
Bare crimp terminal		Used to connect power cables.

Procedure

Strip the adhesive tape off the main cable and pigtail.
Use a cable stripper to peel off a 300 mm long section of the outer sheath from one end of a hybrid cable 2.0 for connecting to a switch, and peel off 300 mm from the other end for connecting to an AP.

Skip this step if the pigtail does not have a rubber layer.
Splice the optical fiber.
1. Find two optical fibers from the main cable and pigtail, remove the middle rubber layer, and cut off the extra aramid yarn to expose the 30 mm long internal cable.
2. Feed an optical fiber through the caps of a fiber splice protector and a heat-shrink tubing.
3. Use a wire stripper to strip the inner rubber layer and the fiber coating layer to expose the 25 mm optical fiber. Then, use the fiber cleaning paper dipped in alcohol to clean the optical fiber.
4. Use a fiber cutter to cut the optical fiber and insert the optical fiber into one side of the fiber splicer.
5. For the pigtails of the same color, put on the caps of a fiber splice protector, strip the inner rubber layer and the coating layer of the optical fiber, insert them into the other side of the fiber splicer, and start fiber splicing.
6. Use a heat shrink tubing to secure the fiber splicing point.
7. Assemble the fiber splice protector. Place the spliced optical fiber into the fiber splice protector, and tighten the caps at both ends.
  - Ensure that the heat shrink tubing has cooled down before you assemble the fusion splice protection sleeve.
  - For the fiber management tray on the front panel, fiber splicing cannot be performed with a fiber splice protector. Otherwise, fiber coiling will be affected.
  - If the fiber splicing point is coiled in the fiber management tray, the fiber splice protector is not required.
8. Repeat the preceding steps to splice the main optical cable and the other optical fiber in the pigtail.
Crimp the power cable.
1. Find two power cables from the main cable and pigtail, and strip the insulation layer to expose a 7 mm copper wire.
2. Insert the copper wires of the power cables of the same color in the main cable and pigtail into the two ends of the bare crimp terminal, and use the ratchet crimping pliers to crimp the copper wires.
  
  When crimping a 17 AWG power cable on site, use a pair of pliers with a cross-sectional area of 1 mm² to 1.5 mm².
  
  When crimping a 21 AWG power cable on site, use the pliers with a diameter of 0.5 mm², or select the corresponding pliers according to the actual situation.
  
  When crimping the power cable, ensure that the side of the crimping pliers is close to the step surface in the middle of the bare crimp terminal. If the insulation tube of the bare crimp terminal is damaged, wrap the bare crimp terminal with insulation tape.
  
  In this way, the assembling operation of the hybrid cable 2.0 is completed.